System and Method of Making Tapered Looped Suture

ABSTRACT

A system for forming a looped suture having a tapered cut is provided. The system includes a base for selectively retaining a portion of thread, a clamping device for receiving a first end of the thread, a tensioning device for receiving a second end of the thread, a welding assembly configured to join a first and second section of the thread to form a loop, and a cutting assembly configured to form a tapered end on the first section of the thread.

CROSS-REFERENCE TO RELATED APPLICATION

The present application claims benefit to and priority from U.S.Provisional Application Ser. No. 61/099,594, filed Sep. 24, 2008, theentire content of which is incorporated herein by reference.

BACKGROUND

1. Technical Field

The present disclosure relates to a method of forming a looped suture.More particularly, the present disclosure relates to a method of forminga looped suture having a tapered surface.

2. Background of Related Art

A method for forming a loop in a suture during a wound closing procedure(surgery) is known. It would be beneficial to have a system and methodfor more effectively forming a loop on a suture prior to engagement oftissue with the suture. It would be further beneficial if the system andmethod could form a tapered end on the loop.

SUMMARY

Accordingly, a system for forming a looped suture having a taperedsurface is provided. The system includes a base for selectivelyretaining a portion of thread, a clamping device for receiving a firstend of the thread, a tensioning device for receiving a second end of thethread, a welding assembly configured to join a first and second sectionof the thread to form a loop, and a cutting assembly configured to forma tapered end on the first section of the thread.

The base may include a suture nest, a pin retaining member, a pin, and apin locking member. The base may include at least one channel forreceiving at least a portion of the second section of the thread. Thepin retaining member may be pivotally mounted to the base. The pin maybe configured to receive a portion of the thread thereabout. The weldingassembly of the system may be configured to weld using ultrasonicenergy.

The cutting assembly of the system may be configured to cut using one ofultrasonic energy, blades and lasers. The cutting assembly may beconfigured to form a tapered end on the first section of thread that isgenerally linear or generally curved. The cutting assembly may beconfigured to form a tapered end on the first section of thread that isconvex or concave. The cutting assembly may also be configured to form atapered end on the first section of thread that is angled downwardstowards a longitudinal axis of the elongate body. Furthermore, thecutting assembly may be configured to form a tapered end on the firstsection of thread that forms an angle of about zero degrees (0°) toabout ninety degrees (90°), preferably, five degrees (5°) to aboutthirty degrees (60°), relative to a longitudinal axis of the elongatedbody. In addition, the cutting assembly may be configured to form atapered end on the first section of thread that is suitable forpenetrating tissue.

Further provided is a method of forming a loop in a suture thread. Themethod includes the steps of providing a loop forming system including,a base for securely retaining a thread to be formed, a welding assemblyfor forming a loop in the thread, and a cutting assembly for forming ataper on an end of the loop, securing a portion of the thread to thebase such that a first section of the thread is maintained adjacent to asecond section of the thread, approximating the welding assembly and thebase towards each other, approximating the welding assembly and baseaway from each other, approximating the cutting assembly and the basetowards each other, and cutting a tapered end on a proximal end of thefirst section of the thread, approximating the cutting assembly and baseaway from each other, and removing the formed suture from the base.

The loop forming system of the method may further include a clampingdevice for receiving a first end of a thread. The loop forming systemmay further include a tensioning device for tensioning a thread once thethread is retained in the base.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the disclosureand, together with a general description of the disclosure given above,and the detailed description of the embodiment(s) given below, serve toexplain the principles of the disclosure, wherein:

FIG. 1A is a side view of a looped suture including a tapered portion;

FIG. 1B is a cross-sectional end view of the looped suture of FIG. 1A,taken along line 1B-1B;

FIG. 1C is an enlarged side view of portion 1C of FIG. 1A;

FIG. 2A is a front view of a base used in the tapered loop formingmethod of the present disclosure;

FIG. 2B is a side view of the base of FIG. 2A;

FIG. 2C is a top view of the base of FIGS. 2A and 2B;

FIG. 3A is a side view of the base of FIGS. 2A-2C loaded with a sutureand including a welding assembly, a suture retaining assembly and asuture tensioning assembly;

FIG. 3B is a top view of the loaded base of FIG. 3A;

FIG. 3C is a cross-section front view of the loaded base of FIGS. 3A and3B;

FIGS. 4A and 4B are enlarged views of FIG. 3C, with the suture in apre-welded (FIG. 4A) and post-welded (FIG. 4B) configuration;

FIG. 5A is a top view of the loaded base of FIGS. 3A-3C, post-weldingand prior to the tapered cut being formed;

FIG. 5B is a cross-sectional front view of the loaded base of FIG. 5A;

FIG. 5C is a cross-sectional side view of the loaded base of FIGS. 5Aand 5B;

FIG. 6A is a cross-sectional front view of the loaded base of FIGS.5A-5C, post-welding and post-cutting of the suture;

FIG. 6B is a cross-sectional side view of the loaded base of FIG. 6A.

DETAILED DESCRIPTION

A method for forming a looped suture including a tapered surface isherein described. Referring initially to FIG. 1A, a looped suture formedin accordance with the method of the present disclosure is showngenerally as looped suture 10. Suture 10 is formed from a monofilamentthread 11; however, it is envisioned that suture 10 may be formedbraided threads, multifilament threads and other surgical fibers.Although shown having a circular cross-sectional geometry, thecross-sectional geometry of thread 11 may be of any suitable shape, suchas, round, elliptical, square, flat, octagonal, and rectangular. Thread11 may be formed of degradable materials, non-degradable materials, andcombinations thereof. Thread 11 may be formed using any technique withinthe purview of those skilled in the art, such as, for example,extrusion, molding and/or gel spinning.

With reference to FIGS. 1A and 1B, looped suture 10 includes a loop 12formed on a distal end 10 b thereof. Loop 12 forms a substantiallyteardrop shape and may be formed of any size. A first section 13 ofmonofilament thread 11 overlays a second section 14 of thread 11 to formloop 12. The adjacent surfaces of first and second sections 13, 14 forma joined segment or joint 15. As shown, joined segment 15 extends beyondfirst section 13 of thread 11. In this manner, first and second sections13, 14 of thread 11 are less likely to separate or peel away from eachother as looped suture 10 is pulled through tissue (not shown).

As will be described in further detail below, first and second sections13, 14 of thread 11 are welded together to form joined section 15.Energy is locally applied to first and second sections 13, 14 of thread11 fusing sections 13, 14 together to form joined segment 15. Varioustypes of energy may be applied to first and second sections 13, 14 toform joined segment 15, including, radio frequency (RF), ultrasonic,laser, electrical arc discharge, and thermal. Alternatively, first andsecond sections 13, 14 of thread 11 may be joined using glues, epoxies,solvents, or other adhesives.

With particular reference to FIG. 1C, a proximal end 13 a of firstsection 13 is angled to form a tapered surface 17. Tapered surface 17angles downwardly towards proximal end 10 a of looped suture 10. Taperedsurface 17 may form an angle a relative to a longitudinal axis “X” ofsecond section 14, between zero degrees (0°) and ninety degrees (90°),and preferably between about five degrees (5°) to about thirty degrees(60°). Tapered surface 17 facilitates insertion of loop 12 into orthrough tissue. Tapered surface 17 may be formed prior to, during orfollowing the joining of first and second sections 13, 14. In oneembodiment, tapered surface 17 is formed such that joined segment 15extends beyond first section 13 of thread 11. In this manner, taperedsurface 17 forms a smooth transition with second section 14 of thread11, thereby decreasing the likelihood that first and second sections 13,14 might separate or peel away from each other as looped suture 10 ispulled through tissue.

Although shown having a substantially planar taper, tapered surface 17may include any number of configurations. For example, tapered surface17 may be beveled, may include a laterally and longitudinally concavetaper, may include a laterally and longitudinally convex taper, or mayinclude any combination thereof. Tapered surface 17 may be selecteddepending on the tissue being sutured and/or the depth loop 12 isdesired to be received within the tissue.

A system for forming loop 12 on distal end 10 b of looped suture 10 willnow be described with reference to FIGS. 2A-6B, and is shown generallyas system 100. System 100 includes a fixture member or base 110, asuture retaining member 120 (FIG. 3A), a suture tensioning member 125(FIG. 3A), a welding assembly 130 (FIGS. 3A-3C), and a cutting assembly140 (FIGS. 5A-6B).

Referring initially to FIGS. 2A-2C, base 110 includes a platform 112, asuture nest 114, a pin retaining member 116, a pin 116 a extending frompin retaining member 116, and a pin lock 118. Platform 112 includes oneor more openings 112 a for securing base 110 to a workstation (notshown) using bolts 112 b or other fixation means. As shown, suture nest114 is integrally formed with platform 112. Alternatively, suture nest114 may be releasably attached or securely affixed to platform 112. Nest114 includes one or more channels 115 extending across a top surface 114a thereof. As will be described in further detail below, channels 115are configured to partially receive a portion of suture thread 11,including second section 14 (FIG. 1). Nest 114 may further includesraised outer portions 113 extending along proximal and distal ends 115a, 115 b of channels 115. Raised outer portions 113 include openings 113a configured to receive two lengths of suture thread 11, adjacent to oron top of one another. As shown, suture nest 114 includes three channels115; however, it is envisioned that suture nest 115 may include one ormore channels 115. In one embodiment, suture nest 115 may be formedwithout a channel. In this manner, the first and second portions ofsuture thread 11 would be received in opening 113 a and are maintainedadjacent to one another through the tension applied by suture tensioningmeans 125 (FIG. 3A).

Still referring to FIGS. 2A-2C, pin 116 a extends from pin retainingmember 116. Pin retaining member 116 is pivotally attached to platform112 such that pin 116 a may be selectively positioned and securelyretained perpendicular to channels 115 along an end thereof (FIG. 3B).Pin lock 118 is pivotally attached to suture nest 114 and is configuredto secure pin 116 a in the perpendicular position adjacent proximal end115 a of channels 115. Alternatively, pin lock 118 may be integrallyformed with suture nest 114. In another alternate embodiment, pinretaining member 116 may be releasably attached or securely affixed toplatform 112. The diameter of pin 116 a may be varied depending on thedesired size of loop 12.

Turning briefly to FIG. 3A, as discussed above, system 100 also includesa suture retaining means 120 and a suture tensioning means 125. Sutureretaining means 120 may include a clamp or other device configured toretain a proximal end 11 a of suture thread 11. Suture tensioning means125 may include a hydraulic or pneumatic tensioning spring, electricalcylinder or other tensioning device configured to receive a distal end11 b of suture thread 11 and to apply tension to suture thread 11 oncethread 11 has been secured to suture nest 114. Suture retaining means120 and suture tensioning means 125 are positioned adjacent distal end115 b of channel 115 to securely receive respective proximal and distalends 11 a, 11 b of suture thread 11 during the forming of loop 12.

With reference to FIGS. 3A-4B, welding assembly 130 includes anultrasonic device 132 operably connected to a generator (not shown) forultrasonically vibrating a die 134 extending from ultrasonic device 132.Die 134 defines a substantially flat suture contacting portion 136. Inan alternative embodiment, die 134 may include a portion 136 configuredto contour first section 13 of suture thread 11. Thus, suture contactingportion 136 may include a concave, convex or beveled surface tocorrespond with a suture thread having a convex, concave or beveledprofile. In one embodiment, welding assembly 130 is operatively mountedon a press assembly (not shown) for approximating die 134 of weldingassembly 130 towards and away from base 110. Alternatively, weldingassembly 130 may be securely mounted relative to base 110 and base 110may be raised and lowered to approximate base 110 towards and away fromdie 134.

Turning now to FIGS. 5A-6B, cutting assembly 140 includes an ultrasonicdevice 142 operably connected to a generator (not shown) forultrasonically vibrating a blade 144 extending from ultrasonic device142. The generator for ultrasonically vibrating die 134 may be the sameor a different generator as is operatively connected to ultrasonicdevice 142 for ultrasonically vibrating blade 144. In one embodiment,blade 144 defines a substantially flat cutting surface 144 a; however,it is envisioned that blade 144 may include a cutting surface ofalternative configurations. Blade 144 may be configured to form aconcave, convex, beveled or otherwise configured taper 17 on loopedsuture 10. Although the following discussion will relate to a cuttingassembly that includes an ultrasonic device 142, it is envisioned thatcutting assembly 140 may be used without ultrasonically vibrating blade144. In this manner, blade 144 may be operably connected to a heater orother apparatus for effecting cutting of suture thread 11. In yetanother embodiment, taper 17 on looped suture 10 may be cut using alaser.

Still referring to FIGS. 5A-6B, in one embodiment, cutting assembly 140is securely mounted relative to base 144 such that cutting assembly 140is maintained stationary as base 110 is approximated towards and awayfrom blade 144. In an alternative embodiment, cutting assembly 140 isselectively positioned relative to base 110, such that cutting assembly140 moved relative to base 110. In either embodiment, at least one ofcutting assembly 140 and base 110 is configured to move laterally withrespect to the other and approximate towards the other. When cuttingassembly 140 is maintained stationary, base 110 is configured to movelaterally, in the direction of arrow A1 (FIG. 6B) and towards cuttingassembly 140, in the direction of arrow A2. When base 110 is maintainedstationary, cutting assembly 140 is configured to move laterally, in thedirection of arrow B1 and towards base 110, in the direction of arrowA2. Movement of base 110 and/or cutting assembly 140 may be computercontrolled or may be effected manually.

The method of forming looped suture 10 utilizing system 100 will now bedescribed with reference to FIGS. 3A-6B. Referring initially to FIG. 3A,a proximal end 11 a of thread 11 is securely locked in a clamp 120.Second section 14 of thread 11 is then positioned within a channel 115of nest 114. Thread 11 is next wrapped around pin 116 a before firstsection 13 of thread 11 is placed on top of or adjacent second section14. A distal end 11 b of thread 11 is then received in tension cylinder125. Tensioning cylinder 125 is then activated to tension thread 11within base 110. To prevent stretching of thread 11 during forming oflooped suture 10, and thereby ensuring consistency and integrity ofthread 11, thread 11 may be formed of a pre-stretched material.

With particular reference now to FIGS. 3C-4B, once first and secondsections 13, 14 are positioned adjacent one another, welding assembly130 is approximated towards suture nest 114. Alternatively, suture nest114 may be approximated towards welding assembly 130. As weldingassembly 130 nears suture nest 114, first section 13 of suture thread 11is received within channel 136 of die 134 until first section 13 engagessuture contacting portion 136 a of channel 136 (FIG. 4A). Ultrasonicdevice 132 may be activated at any point during this process toultrasonically vibrate die 134. The downward pressure exerted on firstand second sections 13, 14 of thread 11 from the continued approximationof die 134 towards nest 114 (FIG. 4B), in combination with ultrasonicvibration of die 134, causes contacting portions of first and secondsections 13, 14 to locally heat, and, in some instances, the contactingportions may begin to melt. Application of ultrasonic energy to sections13, 14 creates joined section 15.

Once first and second sections 13, 14 are fused to create joined section15, welding assembly 130 may be approximated away from suture nest 114.With looped suture 10 remaining secured to base 110, welding assembly130 may then be replaced or exchanged for cutting assembly 140 tocomplete the tapered cutting of proximal end 13 a of first section 13.Alternatively, looped suture 10 may be removed from base 110 and affixedto a separate mount (not shown) to complete the taper forming process.

With reference now to FIGS. 5A-6B, once cutting assembly 130 is properlypositioned in relation to base 110, base 110 is approximated towardscutting assembly 140. Alternatively, cutting assembly 140 may beapproximated towards base 110. Ultrasonic device 142 may be activated atany time prior to or during approximation of cutting assembly 140towards base 110. With particular reference to FIG. 6B, the travel ofbase 110 in relation to cutting assembly 140 includes an upwardmovement, as indicated by arrow A₁ and lateral movement, as indicated byarrow A₂. In an alternative embodiment, cutting assembly 140 is moved ina downward movement, as indicated by arrow B₁ and a lateral movement, asindicated by arrow B₂. The rate at which base 110 moves relative tocutting assembly 140 may be varied depending on the desiredconfiguration of tapered surface 17 (FIG. 1C). In this manner, when thelateral movement is increased relative to the up/down movement, taperedsurface 17 defines an angle a (FIG. 1C) of a lesser degree. Conversely,when the lateral movement of is decreased relative to the up/downmovement, angle a of tapered surface 17 is increased. In eitherembodiment, cutting assembly 130 and base 110 are approximated towardone another until blade 144 completely severs first section 13 of thread11. Distal end 11 b of thread 11 is then pulled away by tension cylinder125.

Cutting assembly 130 and base 110 are then approximated away from eachother and looped suture 10 is removed from pin 116 a. Suture 10 mayinclude flash or debris (not shown) formed during the welding and/orcutting process. The flash may need to be removed before looped suture10 may be used.

Although the illustrative embodiments of the present disclosure havebeen described herein with reference to the accompanying drawings, it isto be understood that the disclosure is not limited to those preciseembodiments, and that various other changes and modifications may beeffected therein by one skilled in the art without departing from thescope or spirit of the disclosure. For example, it is envisioned thatsystem 100 may include more than one welding assembly 130 and acorresponding number of cutting assemblies 140 to produce more than onesuture 10 per activation. It is further envisioned that system 100 mayinclude a separate base for maintaining suture 10 during the cuttingprocess.

1-15. (canceled)
 16. A method of forming a loop in a suture, the methodcomprising the step of: providing a loop forming system including, abase for securely retaining the suture to be formed, a welding assemblyfor forming a loop in the suture, and a cutting assembly for forming ataper on an surface of the loop; securing a portion of the suture to thebase such that a first section of the suture is maintained adjacent to asecond section of the suture; approximating the welding assembly and thebase towards each other; approximating the welding assembly and baseaway from each other; approximating the cutting assembly and the basetowards each other; and cutting a tapered surface on a proximal end ofthe first section of the suture; approximating the cutting assembly andbase away from each other; and removing the formed suture from the base.17. The method of claim 16, wherein the loop forming system furtherincludes a clamping device for receiving a first end of a suture. 18.The method of claim 16, wherein the loop forming system further includesa tensioning device for tensioning the suture once the suture isretained in the base.
 19. A medical device formed from the method claim16.